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Where Were We In 2006? A number of environmental impacts had already been addressed VOCs and Hazardous Waste Began full implementation of an Environmental Management System (EMS) in September, 2006 Needed an environmental “Goal” for 2007 One significant environmental aspect that had not been addressed was “water usage” Very busy! Lots of production on two shifts

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Parts Washer Cross Section An overhead conveyor takes a cylinder through a series of stages comprised of water or chemical and water. Water, temp. and chemical concentration are controlled with electronic systems

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Process Water Installed 6 new meters Pictured is a Neptune Trident T-10 Added a digital display to several meters when the location of the meter made data collection difficult

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Discharge Water Signet 2551 Magmeter Signet 8550 Transmitter

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Sump Layout The process water from each plant is directed to a sump with a float- activated sump pump. Waste water must remain in contact with Magmeter sensor (use loop, check valve or combination)

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Other “Handy” Suggestions Remove the handles from flow control valves (Universal solution from maintenance dept.) Discourages employees, vendors, etc. from increasing flow to fix a temporary problem Add solenoid switches to the flow valves which are interlocked with the main power to a location Very useful when combined with removing handles

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How Much Did This Cost? Approximately $3,000 Three sump meters (eventually added a fourth) Six process input meters Used existing labor to install meters Maximum of 10 minutes needed to read meters and update “flow” data each day Installation took one months to complete and trouble- shoot Digital meters require calibration Dial meters purchased had different units displayed (gallons, 100 gallons, cubic feet)

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What Does The Data Look Like? What we used to know What we know now

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Results (cont.) Decreased chemical consumption Phosphoric Acid Potassium Hydroxide Decreased natural gas four parts washers 3 million fewer gallons of water that need to be heated from 60 degrees to 120 degrees Decreased the number of required sampling events from six to four each year Coincided with permit renewal

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Savings Summary Resources Dollar$ Water 7.3 gallons per cylinder ‘ gallons per cylinder ‘08 Reduced annual consumption by almost 3 million gallons Natural Gas Annual reduction of 693 million BTU Chemicals Annual reduction of 15,000 to 20,000 pounds of corrosives Water Reduced water and sewer bills by $3,000 annually Natural Gas Reduced natural gas consumption associated with water heating by $5,390 annually Chemicals Reduced chemical purchases by an average of $28,000 annually Total Average yearly savings: $36,390 Per cylinder savings: $0.05

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Of Note Cleaning frequency of washer stages stayed at approximately 3 months We expected this to increase, but it stayed the same. Reducing flow may cause other problems so proceed slowly Quality issues (none yet) NOVs (we had to implement weekly vacuuming of one washer / sump where FOG is a problem) Involve your supplier Training, usage reports, they can be great advocates

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Recommend Communicate Results Periodic updates to management and supervisors Lets them know something is being measured! Frequent updates to maintenance staff and supervisors If you know what is “normal”, you typically find problems before operations folks notice. Periodic updates to all employees Keep beating the drum that water conservation is important. That creates a plant full of people looking for wasted resources.

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P2 and Water Reduction For MTE, this project began with low expectations (it was low hanging fruit). Expect pleasant surprises if you begin to measure and reduce water consumption. Immediate $aving$ Stop wasting chemicals Reduced risk with handling hazardous materials

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P2 and Water Reduction Would we have decreased the flow of water through our processes without this goal? Not likely. Usage was a function of time (rate based) and chemical concentrations chase the water. If we had not set this goal in more prosperous times, we could still be spending $112k on chemicals instead of the $19k we expect to spend this year.

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Would Also Suggest Joining Indiana Partners for Pollution Prevention Environmental Stewardship Program (EMS) Both programs help provide validity to your claims of P2 in a sea of green-washing. Both programs require annual reports that will help you identify some of these “unexpected” results.